US20100304080A1 - Elastic composite - Google Patents

Elastic composite Download PDF

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Publication number
US20100304080A1
US20100304080A1 US12/854,221 US85422110A US2010304080A1 US 20100304080 A1 US20100304080 A1 US 20100304080A1 US 85422110 A US85422110 A US 85422110A US 2010304080 A1 US2010304080 A1 US 2010304080A1
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US
United States
Prior art keywords
nonwoven
elastic
elastic composite
composite according
elastic film
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/854,221
Inventor
Kevin P. Black
Dickie J. Brewer
Donald H. Lester, Jr.
Thierry Marche
Original Assignee
Black Kevin P
Brewer Dickie J
Lester Jr Donald H
Thierry Marche
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to US83999806P priority Critical
Priority to US88931107P priority
Priority to US11/840,407 priority patent/US7794819B2/en
Application filed by Black Kevin P, Brewer Dickie J, Lester Jr Donald H, Thierry Marche filed Critical Black Kevin P
Priority to US12/854,221 priority patent/US20100304080A1/en
Publication of US20100304080A1 publication Critical patent/US20100304080A1/en
Application status is Abandoned legal-status Critical

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/144Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00Other non-woven fabrics
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0822Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1412Infrared [IR] radiation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815Hot melt adhesives, e.g. thermoplastic adhesives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/20Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/344Stretching or tensioning the joint area during joining
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43Joining a relatively small portion of the surface of said articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/472Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially flat
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0854Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns in the form of a non-woven mat
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/48Wearing apparel
    • B29L2031/4871Underwear
    • B29L2031/4878Diapers, napkins
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00Condition, form or state of the layers or laminate
    • B32B2305/10Fibres of continuous length
    • B32B2305/20Fibres of continuous length in the form of a non-woven mat
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/51Elastic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/718Weight, e.g. weight per square meter
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/08Dimensions, e.g. volume
    • B32B2309/10Dimensions, e.g. volume linear, e.g. length, distance, width
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2555/00Personal care
    • B32B2555/02Diapers or napkins
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284Application of adhesive
    • B32B37/1292Application of adhesive selectively, e.g. in stripes, in patterns
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24025Superposed movable attached layers or components
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24752Laterally noncoextensive components
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24752Laterally noncoextensive components
    • Y10T428/2476Fabric, cloth or textile component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24777Edge feature
    • Y10T428/24793Comprising discontinuous or differential impregnation or bond
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24826Spot bonds connect components
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/601Nonwoven fabric has an elastic quality
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/601Nonwoven fabric has an elastic quality
    • Y10T442/602Nonwoven fabric comprises an elastic strand or fiber material

Abstract

An elastic composite includes a first nonwoven, a second nonwoven, and two elastic films sandwiched between the first and second nonwoven. The elastic composite also includes a lateral edge portion where the first nonwoven is bonded to the second nonwoven, a lane between the elastic films that is free of the elastic films, and a first bond joining the first nonwoven to the elastic film, and a second bond joining the second nonwoven to the elastic film. The elastic composite may be used as a component of a disposable garment.

Description

    RELATED APPLICATIONS
  • This divisional application claims the benefit of co-pending application Ser. No. 11/840,407 filed Aug. 17, 2007 which, in turn, claimed the benefit of earlier-filed, co-pending U.S. Provisional application Nos. 60/839,998 filed Aug. 24, 2006 and 60/889,311 filed Feb. 12, 2007.
  • FIELD OF THE INVENTION
  • The instant invention is directed to an elastic composite for use in disposable garments, particularly as a side panel (or ear) or a tab of a disposable diaper.
  • BACKGROUND OF THE INVENTION
  • Disposable garments, for example diapers or training pants, are known. Such garments may have side panels (or ears) and/or tabs. The side panels and/or tabs may be made from elastic composites. Elastic composites typically comprise various combinations of nonwovens and elastic materials, each combination designed to obtain a specific solution to a particular problem. Often, these elastic composites require some type of mechanical work to activate the composite.
  • Examples of elastic composites (also known as elastic laminates) may be found in U.S. Pat. Nos. 6,255,236 and 6,726,983. U.S. Pat. No. 6,255,236 discloses an elastic laminate where two nonwovens sandwich an elastic web, and the laminate has at least one elastic lane and at least one stiffened lane. U.S. Pat. No. 6,726,983 discloses an elastic laminate where two nonwovens sandwich an elastic film, and the elastic film is extrusion coated onto one nonwoven and is thermally bonded to the other nonwoven.
  • There is an on-going effort in the disposable garment industry to provide new elastic composites with a balance of physical and esthetic properties and cost. Accordingly, there is a need for new elastic composites.
  • SUMMARY OF THE INVENTION
  • An elastic composite includes a first nonwoven, a second nonwoven, and two elastic films sandwiched between the first and second nonwovens. The elastic composite also includes a lateral edge portion where the first nonwoven is bonded to the second nonwoven, a lane between the elastic films that is free of the elastic films, and a first bond joining the first nonwoven to the elastic films, and a second bond joining the second nonwoven to the elastic films. The elastic composite may be used as a component of a disposable garment.
  • DESCRIPTION OF THE DRAWINGS
  • For the purpose of illustrating the invention, there is shown in the drawings a form that is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
  • FIG. 1 is a schematic illustration of a representative disposable garment, e.g., a diaper.
  • FIG. 2 is a schematic illustration of a second representative disposable garment, e.g., a diaper.
  • FIG. 3 is a top plan view of an embodiment of the instant invention, parts broken away for clarity.
  • FIG. 4 is an exploded sectional view of a first embodiment of the instant invention taken along sectional lines A-A of FIG. 3.
  • FIG. 5 is an exploded sectional view of a second embodiment of the instant invention taken along sectional lines A-A of FIG. 3.
  • FIG. 6 is an exploded sectional view of a third embodiment of the instant invention taken along sectional lines A-A of FIG. 3.
  • FIG. 7 is an exploded sectional view of a fourth embodiment of the instant invention taken along sectional lines A-A of FIG. 3.
  • FIG. 8 is an exploded sectional view of a fifth embodiment of the instant invention taken along sectional lines A-A of FIG. 3.
  • FIG. 9 is a schematic illustration of a process for making the instant invention.
  • DESCRIPTION OF THE INVENTION
  • Referring to the drawings, wherein like elements have like numerals, there is shown in FIGS. 1 and 2 representative disposable garments, diapers 10 and 30.
  • In FIG. 1, diaper 10 generally comprises a rear waist portion 12, a front waist portion 14, and an interconnecting portion 16. At the lateral edges of the rear waist portion 12, there are affixed side panels (or ears) 18. At the distal ends of the side panels 18, tabs 20 may be affixed thereto. At the distal ends of tab 20, fastening device 22 may be affixed thereto. On the exterior surface of front waist portion 14, a mating fastening device 24 may be disposed (shown as two elements, but may be a continuous element). Fastening device 22 and mating fastening device 24 co-operate to releasably secure diaper 10 about a wearer, as is well known. Fastening device 22 and mating fastening device 24 may be any known fastening mechanism. Such known fastening mechanisms include, but are not limited to, hook and loop fasteners and adhesive fasteners. In diaper 10, side panels 18 may be elastic (e.g., stretchable in a direction away from rear waist portion 12), so that the diaper may be securely fit to the wearer, and tabs 20 may be non-elastic.
  • In FIG. 2, diaper 30 generally comprises a rear waist portion 32, a front waist portion 34, and an interconnecting portion 36. At the lateral edges of the rear waist portion 32, there are affixed side panels (or ears) 38. At the distal ends of the side panels 38, tabs 40 may be affixed thereto. At the distal ends of tab 40, fastening device 42 may be affixed thereto. On the exterior surface of front waist portion 34, a mating fastening device 44 may be disposed (shown as two elements, but may be a continuous element). Fastening device 42 and mating fastening device 44 co-operate to releasably secure diaper 30 about a wearer, as is well known. Fastening device 42 and mating fastening device 44 may be any known fastening mechanism. Such known fastening mechanisms include, but are not limited to, hook and loop fasteners and adhesive fasteners. In diaper 30, side panels 18 may be non-elastic, and tabs 20 may be elastic (e.g., stretchable in a direction away from rear waist portion 32), so that the diaper may be securely fit to the wearer.
  • Referring to FIG. 3, the instant invention, an elastic composite 50, is shown. Elastic composite 50 generally comprises a first (or bottom) nonwoven 54, a second (or upper) nonwoven 56, and a first (or right) elastic film 58 and second (or left) elastic film 60 sandwiched between the first nonwoven 54 and second nonwoven 56. The elastic composite 50 generally comprises two lateral edge portions 62, two stretch zones 64 and a lane 66 (lane 66 is divided by a center line 52 which is shown for reference). In the lateral edge portion 62, the first nonwoven 54 and the second nonwoven 56 may be bonded together (discussed in greater detail below). In the stretch zone 64, the first and second nonwovens 54, 56 may be bonded to the upper and lower surfaces of the elastic films 58, 60 (discussed in greater detail below).
  • The first and second nonwovens 54, 56 may be identical materials. These nonwovens may be any nonwoven. In one embodiment, the nonwoven has a basis weight in the range of 10-40 g/m2, and in another embodiment, in the range of 22-30 g/m2. The nonwoven, in one embodiment, is inelastic and highly extensible in the cross machine direction (CD). In one embodiment, the nonwoven has a CD extension at peak load of at least 200%. These nonwovens may be further characterized, in another embodiment, by their CD/MD (CD-cross machine or transverse direction; MD-machine direction) elongation ratio which may be at least 1:1, or at least 3:1, or in the range of 3-6:1, or in the range of 4-5:1. In one embodiment, the nonwoven is a point-bonded, carded nonwoven or spunlaced nonwoven produced from staple fibers. The staple fibers may be any material, for example, polyester (e.g., PET), polyolefin (e.g., PP), or a blend of both. The nonwoven may have apertures. An example of the point-bonded carded nonwoven is FPN 571D available from Fiberweb of Simpsonville, S.C. or SAWABOND 4132 (22 g/m2) from Sandler AG of Schwarzenbach, Germany. An example of the spunlaced nonwoven is SAWATEX® 2628 available from Sandler AG of Schwarzenbach, Germany.
  • The elastic films 58, 60 are, in one embodiment, identical to one another. The elastic films may be made from any elastomeric polymer. In one embodiment, the elastomeric polymers may be styrenic block copolymers. Styrenic block copolymers include, but are not limited to, SIS (styrene-isoprene-styrene) block copolymers, SBS (styrene-butene-styrene) block copolymers, and combinations thereof. The elastic film may have a basis weight, in one embodiment, of 40-100 g/m2, and in another, 50-70 g/m2. The elastic film may be further characterized by CD elongation of at least 200%.
  • The adhesive used in the bonding discussed above may be any adhesive. In one embodiment, the adhesive is a hot melt, non-elastic adhesive. Alternatively, adhesive may be replaced with bonding (e.g., thermal, ultrasonic, and/or infrared with or without binder fibers in the nonwoven).
  • The instant invention, elastic composite 50, shall be discussed in further detail below with regard to the embodiments shown in FIGS. 4-8.
  • In FIG. 4, elastic composite 50′ is shown. In lateral edge portions 62, the first nonwoven 54 and the second nonwoven 56 are bonded together via lateral edge bonds 68. The lateral edge bonds 68 are formed from the adhesive discussed above. While in each lateral edge portion 62 there is shown two layers of adhesive (forming bonds 68), the invention is not so limited and, for example, a single layer of adhesive (applied to either nonwoven) may be used. Lateral edge bonds 68, in one embodiment, may be a continuous layer of adhesive (i.e., the adhesive covers the length and width of the lateral edge portions), whereby the nonwovens, which are inelastic but extensible, are generally fixed (i.e., prevented or substantially prevented from extension). Lateral edge bonds 68, in another embodiment, may be in the form of a grid or cross-hatching of lines of adhesive, or any other pattern intended to generally fix the nonwovens in the lateral edge portions 62. In one embodiment where the width of the elastic composite is 170 mm, the adhesive weight of the lateral edge bonds 68 is 8-9 g/m2.
  • Likewise, in lane 66, the first nonwoven 54 and the second nonwoven 56 are bonded together via lane bonds 72. The lane bonds 72 are formed from the adhesive discussed above. While in lane 66 there is shown two layers of adhesive (forming bonds 72), the invention is not so limited and, for example, a single layer of adhesive (applied to either nonwoven) may be used. Lane bonds 72, in one embodiment, may be a continuous layer of adhesive (i.e., the adhesive covers the length and width of the lane), whereby the nonwovens, which are inelastic but extensible, are generally fixed (i.e., prevented or substantially prevented from extension). Lane bonds 72, in another embodiment, may be in the form of a grid or cross-hatching of lines of adhesive, or any other pattern intended to generally fix the nonwovens in the lane portion 66. In one embodiment where the width of the elastic composite is 170 mm, the adhesive weight of the lane bond 78 is 2-3.2 g/m2.
  • In stretch zones 64, the first nonwoven 54 and the second nonwoven 56 are bonded to elastic films 58, 60 via stretch zone bonds 70. The stretch zone bonds 70 are located between the first nonwoven 54 and the elastic films 58, 60, and between the second nonwoven 56 and the elastic films 58, 60, as shown. The stretch zone bonds 70 are formed from the adhesive discussed above. The stretch zone bond 70 consists of a plurality of adhesive bonds, whereby when the elastic composite is stretched in the CD, the nonwoven may extend with the elastic film, and when the elastic composite is relaxed, the nonwoven may bulk. The stretch zone bonds 70, in one embodiment, may be a plurality of continuous lines of adhesive extending in the MD (in the drawing, this is illustrated by a horizontal line of dots). The stretch zone bond 70, in another embodiment, may be a plurality of discontinuous (e.g., dots) lines of adhesive extending in the MD (in the drawing, this is illustrated by a horizontal line of dots). The elastic films 58, 60 may extend to the lateral edges of the stretch zone 64 or may extend slightly over the lateral edges of the stretch zone 64. Instead of lines of adhesive, a continuous film of adhesive of various weights/volumes/densities of adhesives may be used (e.g., a pattern of high density adhesive lines with lower densities there between). In one embodiment, the lines of adhesive may have a width in the range of 0.5-1.0 mm or 0.5-0.55 mm. In one embodiment, the center-to-center line of adhesive spacing may be in the range of 2.0-2.5 mm.
  • In FIG. 5, elastic composite 50″ is shown. Elastic composite 50″ is the same as elastic composite 50′ (of FIG. 4), except as follows. A stiffener 74 is added to lane 66 between the first nonwoven 54 and the second nonwoven 56. Stiffener 74 is added to provide additional mechanical strength to lane 66. Lane 66 may be the portion of the elastic composite that is affixed to the disposable garment or the fastener may be affixed thereto, and as such may require additional mechanical strength to facilitate attachment to the garment in assembly of the garment and/or use of the garment. Stiffener 74 is bonded to the first nonwoven 54 and the second nonwoven 56 via lane bonds 72, as discussed above. Stiffener 74 is a non-extensible material (non-extensible with regard to the elastic films 58, 60). Stiffener 74 may be a film or nonwoven. In elastic composite 50″, stiffener 74 extends slightly beyond the lateral edges of lane 66 and overlaps (but may not be bonded thereto) the elastic films 58, 60.
  • In FIG. 6, elastic composite 50′″ is shown. Elastic composite 50′″ is the same as elastic composite 50″ (of FIG. 5), except as follows. Stiffener 74 does not overlap elastic films 58, 60, and when the elastic composite 50′″ is assembled, the lateral edges of stiffener 74 are adjacent to or abut with their respective lateral edge of the elastic films.
  • In FIG. 7, elastic composite 50″″ is shown. Elastic composite 50″″ is the same as elastic composite 50′ (of FIG. 4), except as follows. In elastic composite 50″″, elastic films 58, 60 are replaced with film 76. Film 76 has three zones, two lateral stretch portions 78 (corresponding to the stretch zones 64) and a center portion 80 therebetween (corresponding to lane 66). The lateral stretch portions 78 are elastic and the center portion 80 is inelastic. Film 76 is a unitary material and may be made by co-extrusion.
  • In FIG. 8, elastic composite 50A is shown. Elastic composite 50A is similar to the foregoing elastic composites, except as follows. Elastic composite 50A has no lane 66. Instead, elastic composite 50A includes elastic film 82 (same materials of construction as prior elastic films) which may be adhered to the first nonwoven 54 and second nonwoven 56 via stretch zone bonds 70, as shown. Elastic composite 50A consists of two lateral edge portions 62 and an intermediate stretch zone 64.
  • Referring to FIG. 9, a process 100 for making elastic composite 50 is illustrated. In extrusion step 102, the elastic films 58, 60 or film 76 is made from polymeric resins in to the extruded material. In cooling step 104, the extruded material is cooled and solidified. In laminating step 106, elastic films 58, 60 or film 76 (and/or stiffener 74 as needed) are laminated between nonwovens 54, 56 (nonwovens 54, 56 being provided from supplies 108). Typically, there is no tension in the laminator (except for the slight tensions necessary to move the films and nonwovens therethrough). Optionally, however, a tension (in the MD) may be added to ‘neck down’ the nonwoven prior to lamination to the film. In stiffening step 110, lane 66 (and/or lateral edge portions 62) may be subject to calendering (either heated or nonheated rollers) to ensure firm bonding therein. Finally, in take-up step 112, the elastic composite 50 may be subjected to inspection, edge trim, winding up, and/or packaging.
  • When used in the disposable garment, the elastic composite may be cut along center line 52; so that one portion may be used on the right side of the garment and the other portion may be used on the left side of the garment. When elastic composite 50 is used as a side panel (or ear), the elastic composite should have a CD elongation of at least 140%. When the elastic composite 50 is used as a tab, the elastic composite should have a CD elongation of at least 35% (to obtain this elongation, it may be necessary to use a continuous adhesive layer for stretch zone bonds 70). The lane portion of the elastic composite is used to fasten the elastic composite to the garment.
  • The present invention may be embodied in other forms without departing from the spirit and the essential attributes thereof, and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicated the scope of the invention.

Claims (23)

1. An elastic composite comprising:
a structure consisting of three lateral sections, said sections being a lateral edge portion, a stretch zone, and a lane, with the stretch zone positioned between the lateral edge zone and the lane, the lateral edge portion and the lane being substantially inextensible in a CD when compared to the stretch zone, and the stretch zone being extensible in the CD when compared to the lateral edge portion or the lane; and the elastic composite further comprising:
a first nonwoven and a second nonwoven sandwiching an elastic film with lateral edges, the first nonwoven and the second nonwoven extending beyond the lateral edges of the elastic film,
in the lateral edge portion, the first nonwoven and the second nonwoven being bonded together so that the lateral edge portion being substantially inextensible in the CD,
in the stretch zone, the first nonwoven being bonded to the elastic film with a plurality of laterally spaced apart, stretch zone bonds that extend in a MD, the second nonwoven is bonded to the elastic film with a plurality of laterally spaced apart, stretch zone bonds that extend in the MD,
in the lane, the first nonwoven and the second nonwoven being bonded so that the lane being substantially inextensible in the CD,
whereby when the elastic composite is stretched in the CD, said nonwovens bonded to the elastic film extend with the elastic film and when the elastic composite is relaxed, said nonwovens bonded to the elastic film bulk.
2. The elastic composite according to claim 1 wherein the stretch zone bonds between either the first nonwoven and the elastic film or the second nonwoven and the elastic film comprise lines of adhesives.
3. The elastic composite according to claim 2 wherein the lines of adhesives may be continuous lines or discontinuous lines.
4. The elastic composite according to claim 2 wherein the adhesive being a hot melt adhesive.
5. The elastic composite according to claim 2 wherein the adhesive being inelastic.
6. The elastic composite according to claim 1 wherein each stretch zone bond having a width in the range of 0.5-1.0 mm.
7. The elastic composite according to claim 6 wherein each stretch zone bond having a width in the range of 0.5-0.55 mm.
8. The elastic composite according to claim 1 wherein a center-to-center stretch zone bond spacing being in the range of 2.0-2.5 mm.
9. The elastic composite according to claim 1 wherein the first nonwoven or the second nonwoven or both being selected from the group consisting of a point bonded carded nonwoven or a spunlaced nonwoven.
10. The elastic composite according to claim 9 wherein the first nonwoven or the second nonwoven or both have a CD/MD elongation ratio of at least 3:1.
11. The elastic composite according to claim 1 wherein the elastic film comprising a styrenic block co-polymer.
12. The elastic composite according to claim 1 where in the lane, the first nonwoven is bonded to the second nonwoven.
13. The elastic composite according to claim 1 where in the lane, a stiffener is bonded between the first nonwoven and the second nonwoven.
14. An elastic composite comprising:
a first nonwoven, said first nonwoven being extensible, but inelastic, said first nonwoven being further characterized by a CD/MD elongation ratio of at least 3:1, said first nonwoven being a point-bonded carded nonwoven made of staple fibers or a spunlaced nonwoven,
a second nonwoven, said second nonwoven being extensible, but inelastic, said second nonwoven being further characterized by a CD/MD elongation ratio of at least 3:1, said second nonwoven being a point-bonded carded nonwoven made of staple fibers or a spunlaced nonwoven,
a first elastic film and a second elastic film, said first elastic film and said second elastic film being laterally spaced apart from one another and sandwiched between said first nonwoven and said second nonwoven, said first elastic film and said second elastic film being bonded to said first nonwoven and said second nonwoven, respectively, by a plurality of continuous lines of a hot melt adhesive extending in the MD direction when said first elastic film and said second elastic film being non-tensioned,
a non-extensible material between said first elastic film and said second elastic film and being sandwiched between and bonded to said first nonwoven and said second nonwoven,
whereby when the elastic composite is stretched in the CD direction, said nonwovens extend with said elastic films and when the elastic composite is relaxed, said nonwovens bulk.
15. The elastic composite of claim 14 wherein said CD/MD elongation ratio being in the range of 4-5:1.
16. The elastic composite according to claim 14 wherein said first nonwoven or said second nonwoven being a spunlaced nonwoven.
17. The elastic composite according to claim 14 wherein said first elastic film or said second elastic film or both comprising a styrenic block co-polymer.
18. The elastic composite according to claim 14 wherein said first elastic film or said second elastic film or both having a basis weight in the range of 50-70 g/m2.
19. The elastic composite according to claim 14 wherein said hot melt adhesive being a non-elastic adhesive.
20. The elastic composite according to claim 14 wherein a line of said plurality of continuous lines having a width in the range of 0.5-1.0 mm.
21. The elastic composite according to claim 14 wherein a line of said plurality of continuous lines having a width in the range of 0.5-0.55 mm.
22. The elastic composite according to claim 14 wherein a center-to-center spacing of said plurality of continuous lines being in the range of 2.0-2.5 mm.
23. The elastic composite according to claim 14 wherein said non-extensible material between said first elastic film and said second elastic film and being sandwiched between said first nonwoven and said second nonwoven and bonded to said first nonwoven and said second nonwoven with a hot melt adhesive.
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US9827696B2 (en) 2011-06-17 2017-11-28 Fiberweb, Llc Vapor-permeable, substantially water-impermeable multilayer article
US9827755B2 (en) 2011-06-23 2017-11-28 Fiberweb, Llc Vapor-permeable, substantially water-impermeable multilayer article
US9765459B2 (en) 2011-06-24 2017-09-19 Fiberweb, Llc Vapor-permeable, substantially water-impermeable multilayer article
US10253439B2 (en) 2011-06-24 2019-04-09 Fiberweb, Llc Vapor-permeable, substantially water-impermeable multilayer article

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CN104771274A (en) 2015-07-15
EP2056762A4 (en) 2012-03-07
US20080051748A1 (en) 2008-02-28
WO2008024739A3 (en) 2008-09-25
EP2056762A2 (en) 2009-05-13
MX2009002004A (en) 2009-03-05
CN102673034B (en) 2015-11-25
ES2440802T3 (en) 2014-01-30
JP5070288B2 (en) 2012-11-07
CN102673034A (en) 2012-09-19
WO2008024739A2 (en) 2008-02-28
EP2056762B1 (en) 2013-11-06
BRPI0715625B1 (en) 2019-01-22
JP2010502473A (en) 2010-01-28
US7794819B2 (en) 2010-09-14
BRPI0715625A2 (en) 2013-07-23

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